Intake Camshaft Balance Shaft

Intake Camshaft Balance Shaft

Special tools, testers and auxiliary items required

• Puller (T10394)

• Puller (T10055)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Always replace the balance shaft after removing it.

Removing

- Remove the balance shaft timing chain. Refer to => [ Balance Shaft Drive Chain ] Balance Shaft Drive Chain.

- Remove the toothed belt from the coolant pump. Refer to => [ Coolant Pump Toothed Belt ] Coolant Pump Toothed Belt.

- Remove the intermediate shaft sprocket bolt - 1 - and the sprocket.






- Remove the intake camshaft balance shaft bolt - 2 - and remove the balance shaft.






If the balance shaft cannot be removed by hand, use the puller (T10394).

- Install the half shell (T10394/1) from the puller (T10394) and rotate it upward in the - direction of the arrow -.






- Install the puller (T10394) and push the sleeve on the puller (T10394) in the - direction of the arrow -.






- Install the puller (T10055) to the puller (T10394) and remove the balance shaft in the - direction of the arrow -.






Installing

• Because of the small clearance between the balance shaft and cylinder block, the balance shaft may need to be cooled in order to install it. Check if the balance shaft can be inserted into the cylinder block without forcing it in. If it cannot, the balance shaft must be cooled before installing it.

• Tightening specifications, refer to => [ Balance Shaft Drive Chain Overview ] Balance Shaft Drive Chain Overview.

- Place the new balance shaft in a freezer for 30 minutes or spray it with commercially available cooling spray.

- Lubricate the balance shaft bearings with engine oil.

- Install the intake camshaft balance shaft.

- Replace the O-ring - 1 - on the intermediate shaft and coat it with engine oil.






- Coat the intermediate shaft with engine oil and insert it. The pin - arrow - on the intermediate shaft must engage in the hole in the cylinder block.

Always replace the intermediate shaft sprocket. Otherwise the backlash will not adjust itself and it could result in engine damage. The new intermediate shaft sprocket has a anti-friction coating that wears off after a short period of use, which automatically adjusts the backlash.

- Mark the tooth face on the intermediate shaft sprocket - arrows -.






- Install the intermediate shaft sprocket; the mark on the balance shaft must be between the marks on the tooth faces.

- Install and tighten the intermediate shaft sprocket bolt - 1 -:






• Tightening specification, refer to => [ Intermediate Shaft Sprocket Bolt Tightening Sequence and Specification ] Balance Shaft Drive Chain Overview.

- Check the marks on the intermediate shaft sprocket and balance shaft - arrow -.

• Due to the ratio, the marks align only after every 7th turn.

- Install the balance shaft timing chain. Refer to => [ Installing ] Balance Shaft Drive Chain.

The rest of the installation is a reverse of the removal procedure, when doing this, note the following:

- Replace the coolant pump drive gear seal. Refer to => [ Coolant Pump Driveshaft Seal ] Coolant Pump Driveshaft Seal.